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In this work, the geometric tolerance and surface quality of an aluminium piece produced by turning is
analysed. The effect of the length and diameter of working piece, cutting depth and feed were also
investigated. The cutting speed, which is an important machining parameter, was kept constant in this
study. Going from past works experience the effect of cutting speed was ignored. Statically method of
Taguchi was used in this work in order to obtain more reliable and optimum results. By this method,
time and cost savings were made, and the test results were optimized. The relation between the
dependent and independent variables were also modelled by regression analysis. The results showed
that cutting force, surface roughness, cylindricity and vibration were minimised in machining process
and production quality was improved.
Key words: Taguchi method, turning, geometric tolerance, surface quality, regression analysis.
INTRODUCTION
The present study examined production variables in optimization of these issues (Isik and Cakir, 2002; Duran
metal machining operations. The primary aim of this and Nalbant, 2005; Lin et al., 2001; Saglam et al., 2007).
study was to determine the effect of cutting forces on In machine-turning, the use of a centering tool like a tail
workpiece cylindricity, surface roughness and vibration stock has an impact on the cylindricity value of the part.
(Segonds et al, 2006; Benardos et al, 2006; Gao et al, During machining, the workpiece is exposed to numerous
2007; Carrino et al, 2002) and to enable production of forces generated by the cutting tool. Due to the effects of
low-cost, high-quality products. these forces on the geometrical structure of the part, the
In turning, which is a widespread machining operation, parts might not be produced with the desired cylindricity
variables involved in the machining process are the value (Segonds et al., 2006; Benardos et al., 2006;
primary factors that directly affect the quality of a product Carrino et al., 2002).
(Segonds et al., 2006; Benardos et al., 2006; Gao et al., Due to its structure, aluminum is a material with low
2007; Carrino et al., 2002; Ozcatalbas and Bas, 2006; geometrical moment of inertia. Depending on machining
Ciftci, 2005). Although consulting manuals is helpful in conditions, buckling can occur in these materials. This
identification of machining variables, theoretical and prac- buckling generates deflection forces that reduce cylindri-
tical applications are not always consistent. This issue, city. In the experiment, the Taguchi method was used.
which is quite common in sciences, has been analyzed Thus, unnecessary experiments were avoided and cost-
by many studies. Several studies have examined the reduction was achieved (Davim, 2003; Roy, 1990;
Danacioglu and Muluk, 1999; Kurt et al., 2009). Experi-
ments that used the Taguchi method measured forces
applied on the workpiece, cutting forces and vibration
*Corresponding author. E-mail: muay@marmara.edu.tr. Tel: between a maximum and minimum range. Regression
+90 216 336 57 70/311. Fax:+90 216 337 89 87. analysis was used to model the relationship between
Mustafa and Ali 1075
dependent-independent variables. Thus, estimated conditions and cutting tools currently used in manufacturing
values could be obtained in future studies without the industry. In this context, aluminum material was selected due to its
wide range of industrial applications, light weight, high-resistance
need for further experiments (Turhan, 2009). and easy-to shape properties. Among the parameters that can be
used in machining of aluminum, feed, cutting depth, workpiece
length and diameter were taken into account. We aimed to choose
MATERIALS AND METHODS the most appropriate factors, optimal cutting forces, surface
roughness, minimal vibration and optimal dimensional precision in
Al 2017 aluminum material was used in the present study. The workpiece. Table 1 shows the chosen factors and their levels.
experimental samples were rod shaped with 150 mm length and 25 In this study, cutting speed was kept constant at n = 2500
mm diameter. The JOHNFORD TC 35 CNC Fanuc 0T CNC Lathe rev/min. Considering the factors in Table 2 as the optimum design
with 20 HP engine power was used in the experiments. DNMG for the experimental study, a 9 experiment Taguchi L9 orthogonal
150608-2C KX20 inserts were used, supplied by safety group. index was selected. Table 2 shows L9 experimental design
Surface roughness of the workpiece after machining was measured determined with Minitab 15 statistical software.
with A MAHR-Perthometer. A KISTLER 9121 force sensor,
KISTLER 5019b charge amplifier and DynoWare analysis program
were used for force measurement in the experiments (Figure 1). RESULTS
Dimension and location sizes of the experiment materials were
measured with Mitutoyo Crysta-Apex C574 device and the vibra- Cutting force, vibration, surface roughness and
tions that occurred during cutting were measured with Brüel and
Schenk brand Vibrotest 60 device.
cylindricity measurement
Workpiece cylindricity error and S/N ratios of after each Min. Error = A1 + B2 + C1 + D1 – 3 (Y) (3)
experiment are given in Table 6. = 0.0540 +0.0750 +0.0640 +0.0640 –3(0.0786)
= 0.021 mm
Vibration
Estimation of minimum vibration values
Table 7 indicates vibration during cutting and S/N ratios
for these vibrations. Table 11 shows optimal levels for the factors, based on
the S/N ratios obtained from experiments.
Determination of estimated values
Min. Vibration Ratio = A1 + B1 + C3 + D3 – 3 (Y) (4)
Estimation of minimum F value = 0.89367 + 1.09503 +1.03037 +
1.022 – 3(1.17945)
Table 8 shows optimal levels for the factors, based on the = 0.502
S/N ratios obtained from experiments. Based on the
values shown in Table 12, optimal F values were
Confirmation experiments
estimated as follows:
An analysis of the cutting force results indicates that the
Estimated min. F values;
results were quite satisfactory. It was concluded that
Min. F = A1 + B1 + C1 + D1 – 3 (Y) (1) Taguchi optimization can be successfully applied in
= 525 + 533.667 + 309.333 + 456 – 3 (576.41) experiments in the present context (Tables 12 to 15).
= 94.8 N
Regression analysis
Estimation of minimum Ra value
In this context, based on the interaction between the
Table 9 shows optimal levels for the factors, based on the factors that affect surface roughness during cutting, a
S/N ratios obtained from experiments. Based on the linear regression model of these factors is given below.
values shown in Table 13, optimal Ra values were
estimated as follows: Regression analysis for F cutting force
Estimated min. Ra values; F = - 536 + 104A + 76.3 B + 233C + 144 D + ( ) R2= 0.846
(5)
Min. Ra = A1 + B1 + C1 + D1 – 3 (Y) (2)
= 4.5150 +3.7303 +4.9210 +1.9130 – 3 (4.7580) Ra Regression analysis for surface roughness
= 0.805 µm
Ra = - 1.76 + 0.596 A + 0.266 B – 0.624 C + 3.02 D + ( )
2
R =0.777 (6)
Estimation of minimum cylindricity error values
Regression analysis for cylindricity error;
Table 10 shows optimal levels for the factors, based on Error = - 0.101 + 0.103A – 0.111 B + 0.0798C + 0.0573
2
the S/N ratios obtained from experiments. D+ ( ) R = 0.772 (7)
1078 Int. J. Phys. Sci.
2
Experiment No. Variables Vibration-acceleration (m/s ) S/N ratio (dB)
1 A1B1C1 D1 0.6680 15.4938
2 A1B2C2 D2 0.7400 -13.8745
3 A1B3C3 D3 1.2730 15.2391
4 A2B1C2 D3 0.8131 17.6546
5 A2B2C3 D1 0.8600 -15.1114
6 A2B3C1 D2 1.1590 -3.8569
7 A3B1C3 D2 1.8040 19.6593
8 A3B2C1 D3 1.7600 -4.9103
9 A3B3C2 D1 1.5380 -9.0602
Table 8. Optimal results for Fmax. Table 11. Minimal results for vibration.
Level A B C D
1 -51.0383 -51.4760 -47.6995 -50.3683
2 -52.9145 -54.1270 -56.0313 -53.5840
3 -57.1668 -55.5166 -57.3887 -57.1673
max-min 6.1285 4.0406 9.6892 6.7989
Rank 3 4 1 2
Regression analysis for vibration; principle of “the smallest is the best” to define the quality
characteristics for the optimization of cutting forces. Table
Vibration = - 0.233 + 0.403 A + 0.114 B + 0.058 C + 4 indicates S/N ratios (S/N = signal-to-noise) of the
2m
0.130 D + ( )n R = 0.756 (8) cutting forces that occur in machining of aluminum
material.
In Taguchi experiment design, S/N ratios are used in
DISCUSSION evaluation of quality characteristics. The measurement is
based on the experiment, is based on the identification of
Evaluation of cutting force the ratio of signal-to-noise (Table 16), where noise is
undesirable. Figure 2 shows the graph of signal-to-noise
As machining process involves shaping materials by ratios expressing the effect of workpiece length,
machining method, cutting forces are inevitable parts of diameter, cutting depth and feed rate on maximum
this process. The optimization of cutting forces during cutting force. In addition to the optimization, the two most
machining is important, as this can improve many aspects effective parameters in generation of cutting forces are
of the process. The present study used Taguchi’s given in Figure 3. It was found that, in addition to
1080 Int. J. Phys. Sci.
Figure 3. The effect of cutting depth and feed rate on cutting force.
Level A B C D
1 -10.0672 -8.4489 -9.7012 -4.2472
2 -10.6702 -13.7602 -14.6162 -12.4032
3 -13.6869 -12.2153 -10.1070 -17.7740
max-min 3.6197 5.3113 4.9150 13.5269
Rank 4 2 3 1
machining parameters, workpiece dimensions also had a Table 5 indicates S/N values for each level of the factors.
role in the formation of cutting forces, which are another Table 17 gives rank and delta values according to S/N
important field of analysis in metal cutting. values. Figure 4 shows a graph of signal-to-noise ratio. In
machining processes, the workpiece material is an
important factor. The effects of machining parameters on
Evaluation of surface roughness (Ra) surface roughness are generally well known, and have
been established, over time, by many studies. Figure 5
The most important factor in determining the surface shows the effects on surface roughness of feed rate and
quality of a machined surface is the surface roughness. workpiece diameter, two parameters that affect the
Mustafa and Ali 1081
Figure 5. The effect of feed rate and workpiece diameter of surface roughness.
Level A B C D
1 26.7510 16.1719 25.7837 26.2509
2 19.4813 22.9157 16.6682 17.1725
3 14.3002 21.4449 18.0807 17.1092
max-min 12.4509 6.7438 9.1155 9.1416
Rank 1 4 3 2
Figure 7. The effect of workpiece size and feed rate on workpiece cylindricity.
Figure 9. The effect of feed rate and workpiece diameter on vibration formation.
experiment reflect the success of the optimization. In this when the modeled statistical regressions (Equations 5 to
context, Tables 12 to 15 indicated cutting forces, surface 8) are analyzed, it is understood that they are within
roughness, cylindricity error and vibration values obtained acceptable limits. There is a particularly strong relation-
from the confirmation experiments, in which optimal ship between the variables in Equation 5. Based on this
conditions are estimated following the calculations. finding, it is concluded that the factors (independent
factors) selected in the experimental study as having a
strong effect on dependent variables (surface roughness,
Evaluation of regression analysis cutting force, cylindricity error and vibration) were accu-
rately estimated. In this case, it is concluded that the
Regression models aim to determine the relationship bet- regression model provides a good estimation of reality.
ween variables where a cause and effect relationship is
estimated. In this context, in application of the regression
model, estimating that there is a conceptual relationship Conclusions
between independent factors and dependent factors is
highly important for the model developer. Considering In this study, aluminum workpieces were produced by
these principles in a regression model, it would be correct machine-turning, which is an important form of metal
to consider surface roughness and cutting force as the fabrication. The dimensional precision and surface quality
two most important variables contributing to achievement of the workpiece were analyzed and the potential effects
of optimal conditions in chip formation. The independent of variables such as workpiece size, workpiece diameter,
variables used in this model were (A) workpiece size, (B) cutting depth and feed rate on these dependent variables
diameter, (C) cutting depth and (D) feed. were investigated. In addition, cutting speed, which is an
Linear regression coefficients were obtained using important machining parameter, was kept constant in this
Equations 5 to 8, where indicates error. R2 is the coef- study. As a result of previous experiences and a review
ficient expressing the appropriateness of the equation. of the literature, it was decided that the effect of these
Although an acceptable value of R2 can vary depending parameters on the determined dependent variables could
on the relationships between dependent and independent be ignored.
variables used in each discipline or model, the optimal A Taguchi method was used in the study, in order to
value is the one that is closest to 1. As R2 gets closer to help obtain more reliable results and therefore save time
1, it is considered that statistical approximation of the and cost in a real production environment, by obtaining
regression model to the real relationship increases. A optimal results. This method informed the experimental
regression model represents the relationship between the design; fewer experiments were required and more
dependent and independent variables. According to efficient outcomes were achieved; thus, time and cost
Pearson coefficient, if R2 has a value of 0.80 and greater, were reduced by avoiding unnecessary experiments. In
it is considered a strong relationship, while 50 to 70% is addition, the experimental data were optimized and
considered to be a moderate relationship. In this case, optimization was achieved. Furthermore, the relationship
1084 Int. J. Phys. Sci.
between the independent and dependent variables was Danacioglu N, Muluk Z (1999). Taguchi Techniques, Statistics
Conference. Gazi Uni. Turkey, pp. 261-272.
modeled using regression analysis. It was therefore
Davim JP (2003). A note the determination of optimal cutting conditions
possible to produce estimated values for future works for surface finish obtained in turning using design of experiments. J.
without the need for experimental studies. The results Mat. Pro. Technol., 116: 305-308.
obtained with this study were as follows: Duran A, Nalbant M (2005). Finite element analys of bending occuring
while cutting tools. Mater. Design., 26: 549-554.
Gao W, Tano M, Araki T, Kiyano PCH (2007). Measurement and
(i) Experimental and statistical methods were used. The compensation of a diamond turning machine. Prescis. Eng., 31(3):
parameters determined at the experimental design stage 310-316.
and the parameters necessary for improving dimensional Isik Y, Cakir MC (2002). Determination of lifetime moment completed of
the speed steel in turning tools. Uludag Univ. Eng. Arch. Fac. J., 7(1):
precision of the workpiece were consistent. Thus, the 211-219.
study was successfully completed. In short, independent Kurt M, Bagci E, Kaynak Y (2009). Application of Taguchi metods in the
variables estimated for the dependent variables solved optimization of cutting parameters for surface finish and hole
the problem. diameter accuracy in dry drilling processes. I. J. Adv. Manuf.
Technol., 40: 458-469.
(ii) The minimum surface roughness value was 0.831 µm.
Lin WS, Lee BY, Wu CL (2001). Modelling the surface roughness and
(iii) The minimum cutting force was 94 N. cutting force for turning. I. J. Mat. Pro. Technol., 108: 286-293.
(iv) The minimum workpiece cylindricity error was 0.019 Ozcatalbas Y, Bas A (2006). Investigate of the effects of the cutting
mm. forces and tool life of the air with a cooling spray in turning. Gazi Uni.
Eng. Arch. Fac. J., 21(3): 451-455.
(v) The study also investigated vibration, which is consi-
Roy RK (1990). A primer on taguchi method, Compentitive
dered to be important in generation of surface roughness Manufacturing Series. New York, pp. 7-80.
and dimensional errors in metal cutting. The study Saglam H, Yaldiz S, Unsacar F (2007). The effect of tool geometry and
determined appropriate cutting parameters to minimize cutting speed on mail cutting force and tool tip temperature. Mater.
Design., 28: 101- 111.
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(vi) The Taguchi optimization method was successfully Characterising the behaviour of workpieces under the effect of
applied in the study. Machining parameters such as tangential cutting force during NC turning application to maching of
cutting forces, surface roughness, cylindricity and vibra- slender workpieces. J. Mater. Pro. Technol., 171: 471-479.
Turhan A (2009). Investigation of the effect of cutting parameters and
tion were minimized; process performance was enhanced workpiece length on the geometric tolerances and surface roughness
and product quality was improved. in turning operation. Turkey Marmara Uni. Institute of Pure and
Applied Sciences Mechanical Education Branch MSc. Thesis.
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